Warning!
- Make sure the motorcycle is stabilised and adequately supported.
- A correctly supported motorcycle will help prevent it from falling.
- An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Note:
- Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on assembly.
- For models fitted with the constant tension hose clips, use T3880207 - Hose Clip Pliers for their removal and installation.
Warning! Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with the pressurised coolant will cause scalds and skin damage.
Perform the following operations:
- Seat - removal
- Battery - removal
- Fuel tank - removal
- Airbox - removal
- Side panel - removal
- Coolant replacement - drainage
Note: Note the routing of the harness for the horn for installation.
1. Disconnect the horn's two electrical connectors and detach the harness from the cooling fan cowl, noting the position of the clips and routing of the harness.
2. Release the fixing and remove the horn.
1. Fixing; 2. Horn
Note: Note the routing of the harness for the cooling fan for installation.
3. Follow the routing of the harness for the cooling fan and disconnect it from the main harness.
4. Release the hose clip and disconnect the bypass hose from the radiator. Discard the clip.
5. Detach the clutch cable retaining clip from the top of the radiator.
1. Hose clip; 2. Bypass hose; 3. Retaining clip; 4. Clutch cable
6. Loosen the hose clips then detach the top and bottom hoses from the radiator.
1. Hose clips; 2. Top hose; 3. Bottom hose
7. Release the radiator lower mounting.
1. Fixing; 2. Radiator lower mounting
Note: Note the position of the rubber air deflector and its retaining plate in relation to the radiator's upper mounting bolts for installation.
8. Release the fixings securing the radiator to the frame. Collect the retaining plate for the air deflector.
1. Fixings; 2. Retaining plate
9. Remove the radiator.